Medical device for manipulating surgical tool

ABSTRACT

A medical device is provided. The medical device includes a shaft motor, a parallel manipulator, a receiving yoke, a runner and a transmission yoke. The shaft motor is configured to generate a mechanical force for manipulating a surgical tool. The parallel manipulator includes an end platform used to support the surgical tool, a base platform used to support the shaft motor and a plurality of limbs coupled between the end platform and the base platform. The limbs are configured to control movement of the end platform. The receiving yoke is coupled to the surgical tool. The runner is slidingly engaged to the shaft motor and configured to receive the mechanical force. The transmission yoke is coupled to the runner and the receiving yoke, and the transmission yoke is configured to transfer the mechanical force to the receiving yoke.

CROSS-REFERENCE TO RELATED PATENT APPLICATION

This application is a continuation application of U.S. application Ser.No. 18/069,230, filed on Dec. 21, 2022, and entitled “MEDICAL DEVICE FORMANIPULATING SURGICAL TOOL”, now pending, which is acontinuation-in-part of U.S. application Ser. No. 17/138,805, filed onDec. 30, 2020 and entitled “MEDICAL DEVICE FOR MANIPULATING SURGICALTOOLS”, now issued as U.S. Pat. No. 11,696,809, the contents of whichare incorporated herein by reference in their entireties.

Some references, which may include patents, patent applications andvarious publications, may be cited and discussed in the description ofthis disclosure. The citation and/or discussion of such references isprovided merely to clarify the description of the present disclosure andis not an admission that any such reference is “prior art” to thedisclosure described herein. All references cited and discussed in thisspecification are incorporated herein by reference in their entiretiesand to the same extent as if each reference was individuallyincorporated by reference.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to a medical device, and moreparticularly to a medical device having a transmission shaft between anend platform and a base platform of a parallel manipulator andconfigured to transfer mechanical force.

BACKGROUND OF THE DISCLOSURE

A parallel mechanism is capable of positioning and orienting an endplatform with up to six or more degrees of freedom. The end platform ofa parallel mechanism can be used to support a medical device, such as adiagnostic device or a surgical instrument. Since the end platformparallel mechanism can be made extremely small, the mechanism can beused either for surgery through a large surgical opening or forendosurgery through a small surgical opening or body orifice.

Because the end platform is capable of being manipulated with highaccuracy and agility, the parallel mechanism is particularly suitablefor use in surgery by remote control. The ability of the mechanism toadjust the position of the end platform makes the mechanism suitable formedical applications that require precision and fine motions. However,having a motor for controlling the surgical instrument mounted at theend platform can cause additional weight and force to be applied to theend platform during operation. The additional weight and force mayaffect the response time and the precision of the range/path of theplanned operation. Therefore, in order to increase the precision of themedical device, there is a need to minimize the force exerted upon theend platform of the parallel manipulator.

SUMMARY OF THE DISCLOSURE

In response to the above-referenced technical inadequacies, the presentdisclosure provides a medical device with a transmission shaft.

In one aspect, the present disclosure provides a medical device,including: a parallel manipulator, an adapter, a transmission shaft anda shaft motor. The parallel manipulator includes an end platform and abase platform mechanically coupled to the end platform. The adapterincludes a body detachably coupled to the end platform and a receivingshaft rotatably supported by the body, and the receiving shaft having areceiving yoke. The transmission shaft is rotatably supported by the endplatform, and the transmission shaft includes a transmission yokeconfigured to transfer mechanical force to the receiving yoke, a firstrod coupled to the transmission yoke, a second rod coupled to the firstrod, a universal joint coupled between the first rod and the second rod,and a runner coupled to the second rod. The shaft motor is configured togenerate mechanical force to drive the transmission shaft, and the shaftmotor has a drive shaft slidably engaged to the runner.

These and other aspects of the present disclosure will become apparentfrom the following description of the embodiment taken in conjunctionwith the following drawings and their captions, although variations andmodifications therein may be affected without departing from the spiritand scope of the novel concepts of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The described embodiments may be better understood by reference to thefollowing description and the accompanying drawings, in which:

FIG. 1 illustrates a three-dimensional view of a medical deviceaccording to some embodiments of the instant disclosure;

FIG. 2 illustrates a cross-sectional view of a medical device accordingto some embodiments of the instant disclosure;

FIG. 3 illustrates an exploded view of a medical device according tosome embodiments of the instant disclosure;

FIG. 4A illustrates a perspective view of a transmission shaft accordingto some embodiments of the instant disclosure;

FIG. 4B illustrates a schematic view of a universal joint according tosome embodiments of the instant disclosure;

FIG. 5 illustrates an exploded view of a transmission shaft according tosome embodiments of the instant disclosure;

FIG. 6 illustrates an exploded view of an adapter according to someembodiments of the instant disclosure;

FIG. 7 illustrates a perspective view of a machine module according tosome embodiments of the instant disclosure;

FIG. 8 illustrates an exploded view of a transmission shaft, a parallelmanipulator, and a machine module according to some embodiments of theinstant disclosure;

FIG. 9 illustrates a cross-sectional view of a drive shaft and a runneraccording to some embodiments of the instant disclosure;

FIG. 10 illustrates a perspective view of a receiving shaft and atransmission yoke according to some embodiments of the instantdisclosure;

FIG. 11 illustrates a cross-sectional view of a force sensor accordingto some embodiments of the instant disclosure; and

FIG. 12 illustrates an exploded view of a force sensor according to someembodiments of the instant disclosure.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

The present disclosure will now be described more fully hereinafter withreference to the accompanying drawings, in which exemplary embodimentsof the disclosure are shown. This disclosure may, however, be embodiedin many different forms and should not be construed as limited to theexemplary embodiments set forth herein. Rather, these exemplaryembodiments are provided so that this disclosure will be thorough andcomplete, and will fully convey the scope of the disclosure to thoseskilled in the art. Like reference numerals refer to like elementsthroughout.

The terminology used herein is for the purpose of describing particularexemplary embodiments only and is not intended to be limiting of thedisclosure. As used herein, the singular forms “a”, “an” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise. It will be further understood that the terms“comprises” and/or “comprising,” or “includes” and/or “including” or“has” and/or “having” when used herein, specify the presence of statedfeatures, regions, integers, steps, operations, elements, and/orcomponents, but do not preclude the presence or addition of one or moreother features, regions, integers, steps, operations, elements,components, and/or groups thereof.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which this disclosure belongs. It willbe further understood that terms, such as those defined in commonly useddictionaries, should be interpreted as having a meaning that isconsistent with their meaning in the context of the relevant art and thepresent disclosure, and will not be interpreted in an idealized oroverly formal sense unless expressly so defined herein.

Exemplary embodiments will be described below with reference to theaccompanying drawings. It should be noted that elements depicted in thereference figures are not necessarily shown to scale; rather, the sameor similar components will be given the same or similar referencenumerals or similar technical terms.

FIG. 1 illustrates a three-dimensional view of a medical deviceaccording to some embodiments of the instant disclosure. FIG. 2illustrates a cross-sectional view of a medical device according to someembodiments of the instant disclosure. FIG. 3 illustrates an explodedview of a medical device according to some embodiments of the instantdisclosure. In some embodiments, the medical device 1 includes aparallel manipulator, a transmission shaft 12, and an adapter 13. Theparallel manipulator includes an end platform 11-1, a base platform11-2, and a plurality of limbs 11-3 operably coupled between the endplatform 11-1 and the base platform 11-2. The transmission shaft 12 isdisposed between the end platform 11-1 and the base platform 11-2.Further, the transmission shaft 12 is rotatably supported by the endplatform 11-1. In some embodiments, the adapter 13 is configured to holda surgical tool T1, such as a drill bit, a trocar, or a saw blade. Insome embodiments, the medical device 1 further includes a sensor system14 disposed between the adapter 13 and the end platform 11-1. The sensorsystem 14 is configured to monitor the force exerted and received by theadapter 13.

In some embodiments, the medical device 1 further includes a housing ahandle 16, and a control module 17. The base platform 11-2 ismechanically attached to the housing 15 and accommodates a machinemodule configured to manipulate the movement of the plurality of limbs11-3, which in turn control the movement of the end platform 11-1. Themachine module 80 includes a plurality of actuators for correspondinglymanipulating the plurality of limbs 11-3 and a shaft motor formanipulating the transmission shaft 11-2. The handle 16 allows a user tohold onto and maneuver the medical device 1 during operation. Thecontrol module 17 allows the user to trigger, halt, or adjust actions ofthe surgical tool T1 or perform other functions of the medical device 1.

Parallel manipulators may be classified based on degree of freedom,number of limbs, order of joints in each limb, and type of actuator. Insome embodiments, the parallel manipulator can be a hexa-axes parallelmanipulator with six degrees of freedom (6-DOF). In some embodiments,the plurality of limbs 11-3 comprises six limbs. In some embodiments,each limb 11-3 has a first joint coupled to an actuator underneath thebase platform 11-2, a second joint coupled to the end platform 11-1, anda third joint between the first joint and the second joint. In someembodiments, the parallel manipulator is a 6-PUS parallel manipulator.In some embodiments, the first joint is a prismatic joint. In someembodiments, the second joint is a spherical joint. In some embodiments,the third joint is a universal joint. The universal joint is formedusing two revolute joints.

In some embodiments, the medical device 1 further includes a firstpositioning unit 18-1 and a second positioning unit 18-2. The firstpositioning unit 18-1 and the second positioning unit 18-2correspondingly include a plurality of markers for emittingelectromagnetic signals, sound wave, heat, or other perceivable signals,and adapters for mounting the markers at particular orientations withrespect to the body of the device. In some embodiments, the markers andadapters are used in cooperation with a spatial sensor for objecttracking functionalities during operation. The second positioning unit18-2 may be disposed in an area between the adapter 13 and the endplatform 11-1. In some embodiments, the second positioning unit 18-2 isdisposed on the end platform 11-1. In some other embodiments, the secondpositioning unit 18-2 is disposed on the adapter 13. In some otherembodiments, the second positioning unit 18-2 is disposed on the toolT1.

FIG. 4A illustrates a perspective view of a transmission shaft accordingto some embodiments of the instant disclosure. FIG. 4B illustrates aschematic view of a universal joint according to some embodiments of theinstant disclosure. In some embodiments, the transmission shaft 40 isrotatably supported by the end platform and slidingly engaged to thebase platform. In some embodiments, the transmission shaft 40 includes atransmission yoke 41 configured to transfer a mechanical force to asurgical tool (i.e., surgical tool T1 in FIG. 1 ), a first rod 44coupled to the transmission yoke 41, a second rod 45 coupled to thefirst rod 44, and a universal joint 46 coupled between the first rod 44and the second rod 45. In some embodiments, the universal joint 46(including connecting shafts in the universal joint) is made of solidmetal with better structural strength, such that the universal joint 46has a longer service life than that of a pliable rod made of a metalspring tube. The universal joint 46 structurally adapts to the appliedforce and returns to its original structure when force is removed. Theuniversal joint 46 is stiff enough to endure and transfer the mechanicalforce from the shaft motor. In one exemplary embodiment, the universaljoint 46 includes a first coupler 46-1 coupled to the first rod 44, asecond coupler 46-2 coupled to the first coupler 46-1, and a thirdcoupler 46-3 coupled between the first coupler 46-1 and the second rod45. As shown in FIG. 4B, the first coupler 46-1 is pivotably coupledwith the second coupler 46-2 through a first connecting shaft S1 and asecond connecting shaft S2, and the first coupler 46-1 is swingable withrespect to the second coupler 46-2 along a first direction D1 and asecond direction D2. In addition, the second coupler 46-2 is pivotablycoupled with the third coupler 46-3 through a third connecting shaft S3and a fourth connecting shaft S4, and the second coupler 46-2 isswingable with respect to the third coupler 46-3 along the firstdirection D1 and the second direction D2. Specifically, the firstcoupler 46-1 rotates in the first direction D1 relative to the secondcoupler 46-2 with the first connecting shaft S1 as one center, androtates in the second direction D2 relative to the second coupler 46-2with the second connecting shaft S2 as another center. In addition, thesecond coupler 46-2 rotates in the first direction D1 relative to thethird coupler 46-3 with the third connecting shaft S3 as one center, androtates in the second direction D2 relative to the third coupler 46-3with the fourth connecting shaft S4 as another center. Since thetransmission shaft 40 is rotatable, neither the first direction D1 northe second direction D2 is a fixed direction, as long as planescorresponding to the first direction D1 and the second direction D2 areperpendicular to one another.

In some embodiments, the universal joint 46 can further include a fourthcoupler 46-4 coupled between the first coupler 46-1 and the secondcoupler 46-2, and a fifth coupler 46-5 coupled between the secondcoupler 46-2 and the third coupler 46-3. As shown in FIG. 4B, the firstcoupler 46-1 is pivotably coupled to the fourth coupler 46-4 about thefirst connecting shaft S1, and the second coupler 46-2 is pivotablycoupled to the fourth coupler 46-4 about the second connecting shaft S2.In addition, the second coupler 46-2 is pivotably coupled to the fifthcoupler 46-5 about the third connecting shaft S3, and the third coupler46-3 is pivotably coupled to the fifth coupler 46-5 about the fourthconnecting shaft S4. In some embodiments, the fourth coupler 46-4 has afirst through hole and a second through hole, and one end of the firstcoupler 46-1, adjacent to the fourth coupler 46-4, has a pair of firstpivot ears 46-11. The first connecting shaft S1 penetrates the pair offirst pivot ears 46-11 and the first through hole, such that the firstcoupler 46-1 is pivotally coupled to the fourth coupler 46-4 about thefirst connecting shaft S1. In addition, one end of the second coupler46-2, adjacent to the fourth coupler 46-4, has a pair of second pivotears 46-21. The second connecting shaft S2 penetrates the pair of secondpivot ears 46-21 and the second through hole, such that the secondcoupler 46-2 is pivotally coupled to the fourth coupler 46-4 about thesecond connecting shaft S2. Correspondingly, the fifth coupler 46-5 hasa third through hole and a fourth through hole, and one end of thesecond coupler 46-2, adjacent to the fifth coupler 46-5, has a pair ofthird pivot ears 46-22. The third connecting shaft S3 penetrates throughthe pair of third pivot ears 46-22 and the third through hole, such thatthe second coupler 46-2 can be pivotally coupled to the fifth coupler46-5 about the third connecting shaft S3. In addition, a pair of fourthpivot ears 46-31 is disposed at one end of the third coupler 46-3 andadjacent to the fifth coupler 46-5, and the fourth shaft S4 penetratesthe pair of fourth pivot ears 46-31 and the fourth through hole, suchthat the third coupler 46-3 is pivotally coupled to the fifth coupler46-5 about the fourth connecting shaft S4. In some embodiments, each oftwo ends of the universal joint 46 has a structure with a stop screwlocked and fastened to a milling plane of a solid metal shaft.Therefore, the defect of an insufficient tightening force due tostructural deformation will not occur to the milling plane underlong-term use. In some embodiments, a maximum distance between the endplatform and the base platform is greater than a sum of lengths of thefirst rod 44, the universal joint 46 and the second rod 45, and aminimum distance between the end platform and the base platform issubstantially the same as the sum of lengths of the first rod 44, theuniversal joint 46 and the second rod 45. In this way, the universaljoint 46 will not be compressed when the medical device is not in use.

In some embodiments, during operation of the medical device, only thefirst rod 44, the universal joint 46 and the second rod 45 are exposedbetween the end platform and the base platform when the end platform andthe base platform are at the minimum distance from each other. In someother embodiments, during operation of the medical device, the first rod44, the universal joint 46, the second rod 45, and a portion of therunner are exposed between the end platform and the base platform whenthe end platform and the base platform are at the minimum distance fromeach other. In other words, the runner is substantially coplanar withthe base platform when the end platform and the base platform are at theminimum distance from each other.

On the other hand, a portion of the runner is exposed between the endplatform and the base platform when the distance between the endplatform and the base platform is greater than the minimum distance.When the end platform and the base platform are at the maximum distancefrom each other, an overlap between the runner and the drive shaft is noless than 5 mm. However, in some other embodiments, an overlap betweenthe runner and the drive shaft may be less than 5 mm when the distancebetween the end platform and the base platform is at the maximum. Inother words, a minimum overlap between the runner and the drive shaft isno less than 5 mm During operation, a force may be applied to theuniversal joint 46 which causes the first coupler 46-1 and the secondcoupler 46-2 to swing, and in response to removing of the applied force,the first coupler 46-1 and the second coupler 46-2 return to theiroriginal states.

In some embodiments, the runner is substantially coplanar with the baseplatform when the end platform and the base platform are at the minimumdistance from each other. Further, the sum of lengths of the first rod44, the universal joint 46 and the second rod 45 is substantially thesame as the minimum distance between the end platform and the baseplatform. In other embodiments, the runner protrudes from the baseplatform when the end platform and the base platform are at the minimumdistance from each other. Further, the sum of lengths of the first rod44, the universal joint 46 and the second rod 45 is less than theminimum distance between the end platform and the base platform. In someother embodiments, the runner is recessed from the base platform whenthe end platform and the base platform are at the minimum distance fromeach other. Further, the sum of lengths of the first rod 44, theuniversal joint 46 and the second rod 45 is greater than the minimumdistance between the end platform and the base platform. However, whilethe distance between the end platform and the base platform is at theminimum, the universal joint 46 is at a normal state. In someembodiments, the normal state of the universal joint 46 is a state inwhich the pliable rod experiences relatively no force, no force isapplied on the universal joint 46, as compared to the swinging state ofthe universal joint 46. Thus, the universal joint 46 maintains itsoriginal shape (i.e., the first coupler 46-1 and the second coupler 46-2do not swing) during the normal state.

In an exemplary embodiment, a length L40 of the transmission shaft 40 issubstantially 11.5 cm (i.e., 11.495 cm). In an exemplary embodiment, thecombined length L42 of the first rod 44, the universal joint 46 and thesecond rod 45 is substantially 5.5 cm (i.e., 5.475 cm). In an exemplaryembodiment, diameters D42 of the first rod 44 and the second rod 45 aresubstantially 0.38 cm. In an exemplary embodiment, a diameter D43 of therunner 43 is substantially 1 cm. In an exemplary embodiment, a lengthL43 of the runner 43 is substantially 3 cm (i.e., 2.995 cm). In anexemplary embodiment, a diameter D41 of a widened part of thetransmission yoke 41 is substantially 1.3 cm. However, theabove-mentioned dimensions are only examples, and should not be used tolimit the scope of the disclosure.

FIG. 5 illustrates an exploded view of a transmission shaft according tosome embodiments of the instant disclosure. In some embodiments, thefirst rod 44, the universal joint 46 and the second rod 45 can becollectively referred to as a universal joint drive shaft 42, and forthe convenience of the following description, the universal joint driveshaft 42 is simplified as a rod in FIG. 5 . The transmission yoke 41 andthe runner 43 correspondingly have a through hole into which theuniversal joint drive shaft 42 is inserted. To physically attach theuniversal joint drive shaft 42 to the transmission yoke 41 and therunner 43, pins 41-21, 41-22, 43-21, and 43-22 are correspondingly used.The pins 41-21 and 41-22 are used to pin or press one end of theuniversal joint drive shaft 42 to an inner surface of the through holeof the transmission yoke 41. In some embodiments, the pins 41-21 and41-22 are disposed orthogonally to each other. The pins 43-21 and 43-22are used to pin or press another end of the universal joint drive shaft42 to an inner surface of the through hole of the runner 43. In someembodiments, the pins 43-21 and 43-22 are disposed orthogonally to eachother. Therefore, orthogonal positioning of the pins 41-21, 41-22,43-21, and 43-22 ensure that the universal joint drive shaft 42 issecurely fastened to the transmission yoke 41 and the runner 43 duringoperation.

In a case of using a pliable rod which is composed of a metal springtube and coupled between the transmission yoke 41 and the runner 43,lifetime is relatively low due to fatigue of the metal spring.Therefore, the pliable rod may be composed of multiple bundles of thinmetal wires wrapped with a spring wire. In addition, the pliable rodmust be maintained at a bending state as it is in use, the rigidity ofthe pliable rod cannot be too stiff. However, a diameter of the springwire of the pliable rod affects the rigidity. To make the pliable rodhave elasticity and bendability, it is necessary to use the spring wirewith a smaller diameter; however, such spring wire does not last long.In addition, the transmission shaft 12 can transmit a rotational torquefrom the shaft motor to the surgical tool T1. However, metal dust may begenerated due to friction between metal surfaces of the spring wirewhile the pliable rod rotates, thus increasing the risk of damaging theinside of the platform. Therefore, in the medical device 1 provided bythe present disclosure, the universal joint 46 can be utilized toconnect the transmission yoke 41 and the sliding member 43, and theuniversal joint 46 can cooperate with the end platform to performmulti-directional movement. The motion capability of six degrees offreedom can be achieved, and the issue of poor lifetime of the pliablerod composed of the metal spring tube can be resolved as well. Inaddition, dust is less likely to be generated by friction as theuniversal joint 46 rotates, thereby reducing the risk of damage to theinterior of the platform.

In some embodiments, the transmission yoke 41 includes a protrusion 41-1configured to transfer a mechanical force to a receiving shaft of theadapter (i.e., adapter 13 in FIG. 1 ). The protrusion 41-1 is configuredto have minimal contact to the receiving shaft of the adapter duringoperation to prevent noise (meaningless or unwanted mechanical forceinput) on the adapter.

As shown in FIG. 5 , the end platform 50 includes a first bearing 51 anda second bearing 52. In some embodiments, the end platform 50 furtherincludes a washer 53 and a retaining ring 54. In some embodiments, thefirst bearing 51 and the second bearing 52 are flanged bearings in whichan extension or a lip on an outer ring of the bearing is designed to aidthe mounting and positioning of the bearing. In some embodiments, aflange of the first bearing 51 is positioned on a surface of the endplatform 50 facing away from the base platform (i.e., positioningbetween the end platform 11-1 and the adapter 13 in FIG. 3 ). In someembodiments, a flange of the second bearing 52 is positioned on asurface of the end platform 50 facing towards the base platform (i.e.,positioning between the end platform 11-1 and the base platform 11-2 inFIG. 3 ).

In some embodiments, the retaining ring 54 is radially installed on agroove 41-4 of the transmission yoke 41. The retaining ring 54 may be aC-ring. In some embodiments, the washer 53 is disposed between retainingring 54 and the second bearing 52 to prevent abrasion of the secondbearing 52. Further, the washer 53 is used to fill the gap between theflange 41-3 of the transmission yoke 41 and retaining ring 54. In someembodiments, the gap between the flange 41-3, the end platform 50, thewasher 53, the first bearing 51, and the second bearing 52 issubstantially removed through the use of the retaining ring 54. Thebearings 51 and 52 may be sandwiched between the flange 41-3 of thetransmission yoke 41 and the retaining ring 54. Thus, the flange 41-3 ofthe transmission yoke 41 and the retaining ring 54 are used to aid themounting and positioning of the transmission yoke 41.

FIG. 6 illustrates an exploded view of an adapter according to someembodiments of the instant disclosure. In some embodiments, the adapterincludes a body and a receiving shaft 66 disposed within and rotatablysupported by the body. The body includes a base 61 and a cover 62mechanically attached to the base 61. The receiving shaft 66 is disposedbetween the base 61 and the cover 62. In some embodiments, the receivingshaft 66 includes a receiving yoke 66-1 and a chuck 66-2 opposite thereceiving yoke 66-1. The chuck 66-2 is configured to hold a surgicaltool (i.e., surgical tool T1 in FIG. 1 ). The chuck 66-2 is aligned witha through hole of the cover 62 where a surgical tool may be inserted.The receiving yoke 66-1 is exposed outside of the adapter. In this way,receiving yoke 66-1 can receive mechanical force from the transmissionshaft. The contact between the receiving yoke 66-1 and the transmissionshaft is designed to be as minimal as possible to prevent generation ofnoise. In some embodiments, a groove (not shown) is formed on thereceiving yoke 66-1 complementary to a protrusion (i.e., protrusion 41-1in FIG. 5 ) of the transmission shaft for receiving the mechanicalforce.

In some embodiments, the adapter further includes a first bearing 63 anda second bearing 64. In some embodiments, the first bearing 63 and thesecond bearing 64 are flanged bearings in which an extension or a lip onthe outer ring of the bearing is designed to aid the mounting andpositioning of the bearing. In some embodiments, a flange of the firstbearing 63 is positioned on a surface of the base 61 facing towards thecover 62. In some embodiments, a flange of the second bearing 64 ispositioned on a surface of the base 61 facing away from the cover 62.

In some embodiments, the adapter further includes a retaining ring 65.In some embodiments, the retaining ring 65 is radially installed on agroove 66-3 of the receiving shaft 66. The retaining ring 65 may be aC-ring. In some embodiments, a diameter of the receiving yoke 66-1 isgreater than a diameter of the chuck 66-2. In this way, the receivingyoke 66-1 has a wider diameter than an inner ring of the bearings 63 and64. The bearings 63 and 64 may be sandwiched between the receiving yoke66-1 and the retaining ring 65. Thus, the receiving yoke 66-1 and theretaining ring 65 are used to aid the mounting and positioning of thereceiving shaft 66.

FIG. 7 illustrates an isometric view of a machine module according tosome embodiments of the instant disclosure. In some embodiments, themachine module 80 is mechanically attached to a base platform 70 of aparallel manipulator. In some embodiments, machine module 80 includes aplurality of actuators 81 configured to control the movement of theplurality of limbs (i.e., limbs 11-3 in FIG. 1 ) of the parallelmanipulator and a shaft motor 82 configured to generate a mechanicalforce for manipulating a surgical tool (i.e., surgical tool T1 in FIG. 1).

In some embodiments, as shown in FIG. 7 , the base platform 70 includesa limb base 71 and a shaft base 72 surrounded by the limb base 71. Thelimb base 71 is used to provide structural support between the pluralityof limbs of the parallel manipulator and the actuators 81 of the machinemodule 80. The shaft base 72 is used to provide structural support forthe shaft motor 82. In some embodiments, a transmission shaft 40 isdisposed within a recess area of the shaft base 72. A portion of theshaft motor 82 may be exposed in the recess area of the shaft base 72.The transmission shaft 40 and the shaft motor 82 may be slidinglyengaged within the recess area of the shaft base 72.

FIG. 8 illustrates an exploded view of a transmission shaft, a parallelmanipulator, and a machine module according to some embodiments of theinstant disclosure. A shaft motor 92 of the machine module is coupled tothe shaft base 91 of the parallel manipulator. In some embodiments, arotor 92-1 of the shaft motor 92 is inserted into a recess area of theshaft base 91. A drive shaft 94 is attached to rotor 92-1 and configuredto move in a same direction as the rotor 92-1. A runner 93 of atransmission shaft is slidingly engaged to the shaft motor 92. In someembodiments, the runner 93 is slidingly engaged to the drive shaft 94,in which the mechanical force generated by the shaft motor istransferred to the runner 93 through the drive shaft 94. The runner 93has an inlet, and a cross-sectional profile of the drive shaft 94 isstructurally complementary to a cross-sectional profile of the inlet.The inlet is configured to slide along the drive shaft 94. Furtherillustration and related explanation for the relation between the driveshaft and the runner shall be disclosed in FIG. 9 .

In some embodiments, a barrel 95 is placed within a recess area of theshaft base 91. The barrel 95 surrounds the runner 93, while the runner93 surrounds the drive shaft 94 when the medical device is assembled.The barrel 95, the runner 93, and the drive shaft 94 are successivelyfitted within each other.

In some embodiments, to reduce friction between the runner 93 and thedrive shaft 94, a material of the runner 93 and the drive shaft 94 aredifferent from each other. A Young's modulus of the drive shaft 94 isdifferent from a Young's modulus of the runner 93. In some embodiments,a material of the runner 93 is steel, and a material of the drive shaft94 is copper. In some embodiments, a material of the runner 93 and thedrive shaft 94 are anti-friction metal-polymers.

In some embodiments, to reduce friction between the runner 93 and thedrive shaft 94, a lubricant is coated on an outer surface of the driveshaft 94. In some embodiments, a lubricant is coated on an inner surfaceof the runner 93. The lubricant may include, at least one of, carbonpowder, lubricating oil, etc.

In some embodiments, to reduce friction between the runner 93 and thebarrel 95, a material of the runner 93 and the barrel 95 are differentfrom each other. A Young's modulus of the runner 93 is different from aYoung's modulus of the barrel 95. In some embodiments, a material of therunner 93 is steel and a material of the barrel 95 is copper. In someembodiments a material of the runner 93 and the barrel 95 areanti-friction metal-polymers.

In some embodiments, to reduce friction between the runner 93 and thebarrel 95, a lubricant is coated on an outer surface of the runner 93.In some embodiments, a lubricant is coated on an inner surface of thebarrel 95. The lubricant may include at least one of carbon powder,lubricating oil, etc.

FIG. 9 illustrates a cross-sectional view of a drive shaft and a runneraccording to some embodiments of the instant disclosure. Arepresentative illustration of the runner 21 and the drive shaft 22 isprovided to assist in description of the sliding engagementtherebetween. The runner 21 has an inlet 21-1. A cross-sectional profileof a surface 22-1 of the drive shaft is structurally complementary to across-sectional profile of the inlet 21-1. The inlet 21-1 is configuredto slide along the drive shaft 22 when necessary during operation of themedical device. In some other embodiments, an overlap between the driveshaft 22 and the runner 21 is needed during operation to ensure thetransfer of mechanical force therebetween. The overlap between the driveshaft 22 and the runner 21 is no less than 5 mm during operation toensure the transfer of mechanical force therebetween. In some otherembodiments, a minimum overlap between the drive shaft 22 and the runner21 is no more than 5 mm. In some other embodiments, a minimum overlapbetween the drive shaft 22 and the runner 21 ranges between 0 to 5 mm.In some further embodiments, a minimum overlap between the drive shaft22 and the runner 21 ranges between 5 mm to 100 mm. In some embodiments,the depth L1 of the inlet 21-1 is greater than the height L2 of thedrive shaft 22. In some other embodiments, the depth L1 of the inlet21-1 is substantially the same as the height L2 of the drive shaft 22.

In some embodiments, the cross-sectional profiles of the inlet 21-1 andthe surface 22-1 of the drive shaft 22 have a polygonal shape. The driveshaft 22 has a plurality of facets that meet each other to form angledintersections. In some embodiments, an intersection between two facetsis rounded or curved to prevent damage during insertion. The inlet 21-1is an enclosed-shaped opening that grips the facets of the drive shaft22. The angle between facets of the drive shaft 22 provide grip to drivethe runner 21.

In some other embodiments, the drive shaft and the runner have differentstructures used for transferring mechanical force. The drive shaft has aprotrusion. The runner has a groove corresponding to the protrusion. Inan assembled medical device, the protrusion of the drive shaft isinserted into the groove of the runner. The height of groove is enoughto allow the protrusion to stay within the groove while the runnerslides away from the drive shaft during operation. The protrusion isconfigured to slide along the corresponding groove. Further, the driveshaft is configured to transfer a mechanical force to the runner througha sidewall of the protrusion of drive shaft tangential to an innersidewall of the groove of the runner when in motion.

In some embodiments, the drive shaft has two protrusions extending inopposite direction from each other. The runner has two groovescomplementary to the two protrusions of the drive shaft. In someembodiments, the drive shaft has a dogbone drive joint and the runner isa drive cup.

FIG. 10 illustrates a perspective view of a receiving shaft and atransmission yoke according to some embodiments of the instantdisclosure. In some embodiments, a transmission yoke 102 of thetransmission shaft has at least one protrusion 102-1. The at least oneprotrusion 102-1 extends from a body 102-2 of the transmission yoke 102.In some embodiments, the protrusion 102-1 is cylindrical in shape. Thereceiving shaft 101 has a receiving yoke 101-1. The receiving yoke 101-1has grooves 101-2 structurally complementary to the at least oneprotrusion 102-1 of the transmission yoke 102. Upon assembly of themedical device, a top portion of the body 102-2 is inserted in arecessed area of the receiving yoke 101-1. During operation, thetransmission yoke 102 is configured to transfer a mechanical force tothe receiving yoke 101-1 through a sidewall of the protrusion 102-1tangential to an inner sidewall of the groove 101-2. In this way, thecontact between the receiving yoke 101-1 and the transmission yoke 102is minimal during operation to prevent the transmission yoke 102 fromgenerating unwanted noise.

In some embodiments, the transmission yoke 102 has two protrusions102-1. The protrusions 102-1 extend from a sidewall of the transmissionyoke 102 in opposite directions from each other. The two protrusions102-1 are 180° apart from each other. The receiving yoke 101-1 has twogrooves 101-2 complementary to the two protrusions 102-1. In the sameway as the two protrusions 102-1, the two grooves 101-2 are disposedopposite of each other. In some embodiments, the transmission yoke 102is a dogbone drive joint and the receiving yoke 101-1 is a drive cup.

During operation, the noise from the transmission shaft is minimized asmuch as possible so as to not cause problems when the motion of thesurgical tool is monitored. In some embodiments, a sensor system can beused to monitor the surgical tool. FIG. 11 illustrates a cross-sectionalview of a force sensor according to some embodiments of the instantdisclosure. FIG. 12 illustrates an exploded view of a force sensoraccording to some embodiments of the instant disclosure. In someembodiments, the sensor system 110 is disposed between the end platform130 and the adapter 120. The sensor system 110 is configured to measureforce of the adapter 120. The sensor system 110 has a through hole wherea receiving shaft 121 rotatably supported by a bearing 122 and atransmission shaft 140 rotatably supported by a bearing 131 meet.

In some embodiments, the sensor system 110 includes a force relay 111and a force transducer 112 mechanically coupled to the force relay 111.The force relay 111 is detachably coupled to the adapter 120. In someembodiments, the force relay 111 has grooves and protrusion thatinterlocks with grooves and protrusion of the adapter 120.

In some embodiments, the force transducer 112 is mechanically attachedto the force relay 111 and the end platform 130 and configured toconvert a force applied to the adapter 120 into an electrical signal. Insome embodiments, the force transducer 112 is mechanically attached tothe force relay 111 and the end platform 130 using fasteners 113embedded around the periphery of the through hole of the forcetransducer 112. In some embodiments, a plurality of holes are formed onthe front surface and back surface of the force transducer 112 tocorrespondingly accommodate fasteners 113 for the force relay 111 andthe end platform 130. In some embodiments, the fasteners 113 for theforce relay 111 interposes with the fasteners 113 for the end platform130. In some embodiments, the fasteners 113 for the force relay 111 arenot aligned and do not have projections that overlap with projections ofthe fasteners 113 for the end platform 130.

In some embodiments, the force transducer 112 is a donut load cell (alsoknown as a load washer or thru-hole load cell). The force transducer 112converts a force such as tension, compression, pressure, or torque intoan electrical signal. In some embodiments, the force applied to theforce transducer 112 is proportional to the change in the electricalsignal.

In some embodiments, the applied force to the adapter 120, aside frompredetermined force and predetermined torque, further includes a forcedeviation and a torque deviation that is measured during operation. Theforce deviation indicates the influence in the direction of thereceiving shaft when the surgical tool disposed on the receiving shaft121 comes in contact with and exerts force on a target object, such asbone, during operation. The torque deviation indicates the influence inthe motion of the receiving shaft when the surgical tool disposed onreceiving shaft 121 comes in contact with and exerts force on targetobject, such as bone, during operation.

In some embodiments, the sensor system 110 is used in controlling theposition and orientation of the surgical tool during operation. In someembodiments, the sensor system is signally connected to a controller.During operation, an operation plan with predetermined range, thepredetermined path, or the combination thereof is received by thecontroller. The sensor system measures the force deviation, the torquedeviation, or the combination thereof. The force deviation and thetorque deviation are deviations from the predetermined range (i.e.,predetermined force and predetermined torque) of the operation plan. Theorientation and position of the surgical tool is adjusted based on theforce deviation and the torque deviation. The orientation and positionof the surgical tool is adjusted by controlling the actuators that movethe parallel manipulator. The movement of the surgical tool is adjustedby controlling the mechanical force from the shaft motor. In someembodiments, the transmission shaft may cause noise on the sensorsystem. Thus, in some embodiments, a low pass filter is furtherelectrically coupled to the sensor system to remove noise.

Therefore, one aspect of the instant disclosure provides a medicaldevice that includes a parallel manipulator, an adapter, a transmissionshaft and a shaft motor. The parallel manipulator includes an endplatform and a base platform mechanically coupled to the end platform.The adapter includes a body detachably coupled to the end platform and areceiving shaft rotatably supported by the body, and the receiving shafthaving a receiving yoke. The transmission shaft is rotatably supportedby the end platform, and the transmission shaft includes a transmissionyoke configured to transfer mechanical force to the receiving yoke, afirst rod coupled to the transmission yoke, a second rod coupled to thefirst rod, a universal joint coupled between the first rod and thesecond rod, and a runner coupled to the second rod. The shaft motor isconfigured to generate mechanical force to drive the transmission shaft,and the shaft motor has a drive shaft slidably engaged to the runner.

In some embodiments, the medical device further comprises a sensorsystem disposed between the end platform and the adapter, the sensorsystem is configured to measure force on the adapter.

In some embodiments, the sensor system comprises a force relaydetachably coupled to the adapter; and a force transducer mechanicallyattached to the force relay and the end platform, and configured toconvert a force applied to the adapter into an electrical signal.

In some embodiments, the transmission yoke has a protrusion and thereceiving yoke has a groove structurally complementing the protrusion.In some embodiments, the transmission yoke is configured to transfer themechanical force to the receiving yoke through a sidewall of theprotrusion, the sidewall being tangential to the groove.

In some embodiments, the runner has an inlet. A cross-sectional profileof the drive shaft is structurally complementary to a cross-sectionalprofile of the inlet. The inlet is configured to slide along the driveshaft.

In some embodiments, the cross-sectional profiles of the inlet and thedrive shaft have a polygonal shape.

In some embodiments, the drive shaft has a protrusion and the runner hasa groove corresponding to the protrusion. In some embodiments, theprotrusion is configured to slide along the groove.

In some embodiments, a minimum overlap between the drive shaft and therunner is no less than 5 mm.

In one embodiment, the universal joint includes a first coupler coupledto the first rod, a second coupler coupled to the first coupler, and athird coupler coupled between the second coupler and the second rod. Thefirst coupler is pivotably coupled with the second coupler through afirst connecting shaft and a second connecting shaft, and the firstcoupler is swingable with respect to the second coupler along a firstdirection and a second direction. The second coupler is pivotablycoupled with the third coupler through a third connecting shaft and afourth connecting shaft, and the second coupler is swingable withrespect to the third coupler along the first direction and the seconddirection.

In some embodiments, the universal joint further includes a fourthcoupler coupled to the first coupler and the second coupler, and a fifthcoupler coupled between the second coupler and the third coupler. Thefirst coupler is pivotably coupled to the fourth coupler rotatably aboutthe first connecting shaft, and the second coupler is pivotably coupledto the fourth coupler rotatably about the second connecting shaft. Thesecond coupler is pivotably coupled to the fifth coupler rotatably aboutthe third connecting shaft, and the third coupler is pivotably coupledto the fifth coupler rotatably about the fourth connecting shaft.

In some embodiments, the medical device further comprises a barrelsurrounding the runner. The barrel, the runner, and the drive shaft aresuccessively fitted within one another.

In some embodiments, a Young's modulus of the drive shaft is differentfrom a Young's modulus of the runner, and the Young's modulus of therunner is different from a Young's modulus of the barrel.

In some embodiments, the medical device further includes a lubricantthat is coated on a surface of at least one of the barrel, the runner,and the drive shaft.

In some embodiments, when the end platform and the base platform have aminimum distance therebetween, the universal joint is in normal state.

In some embodiments, the force transducer is a donut load cell.

In some embodiments, the adapter further has a bearing configured torotatably attach the receiving shaft to the body. In some embodiments,the end platform further has a bearing configured to rotatably attachthe transmission shaft to the end platform.

Those skilled in the art will readily observe that numerousmodifications and alterations of the device and method may be made whileretaining the teachings of the present disclosure. Accordingly, theabove disclosure should be construed as being limited only by the metesand bounds of the appended claims.

What is claimed is:
 1. A medical device, comprising: a shaft motorconfigured to generate a mechanical force for manipulating a surgicaltool; a parallel manipulator, including: an end platform used to supportthe surgical tool; a base platform used to support the shaft motor; anda plurality of limbs coupled between the end platform and the baseplatform, wherein the plurality of limbs are configured to controlmovement of the end platform; a receiving yoke coupled to the surgicaltool; a runner slidingly engaged to the shaft motor, wherein the runneris configured to receive the mechanical force; and a transmission yokecoupled to the runner and the receiving yoke, wherein the transmissionyoke is configured to transfer the mechanical force to the receivingyoke.
 2. The medical device according to claim 1, wherein the runner andthe shaft motor are slidably engaged within a recess area of the baseplatform.
 3. The medical device according to claim 1, wherein themechanical force generated by the shaft motor is transferred to therunner through a drive shaft, and the runner is configured to be capableof sliding along the drive shaft.
 4. The medical device according toclaim 1, wherein the receiving yoke is coupled to the surgical toolthrough a chuck, and the chuck is configured to hold the surgical tool.5. The medical device according to claim 4, wherein the receiving yokeand the chuck are rotatably attached to a body, and the body is coupledto the end platform.
 6. The medical device according to claim 1, whereinthe end platform has a bearing, and the bearing is configured torotatably attach the runner and the transmission yoke to the endplatform.
 7. The medical device according to claim 1, wherein thetransmission yoke has at least one protrusion, and transfers themechanical force to the receiving yoke through the at least oneprotrusion.
 8. The medical device according to claim 7, wherein thereceiving yoke has at least one groove corresponding to the at least oneprotrusion, and receives the mechanical force through the at least onegroove.
 9. The medical device according to claim 4, further comprising:a plurality of actuators coupled to the plurality of limbs, wherein theplurality of actuators are configured to control movement of theplurality of limbs.
 10. The medical device according to claim 9, whereinthe base platform is further used to provide structural support betweenthe limbs and the actuators, and the receiving yoke and the chuck rotatethe surgical tool according to the mechanical force.